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Welding, Cutting, and Brazing

Texas Department of Insurance, Division of Workers' Compensation


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HS03-004C (10-16) 2
Table of Contents
Frequently Cited Standards in General Industry ......................................................................................... 1
Welding, Cutting, and Brazing Checklist – General Industry ..................................................................... 2
Table 1: Ventilation Requirements – General Industry ................................................................................ 7
Frequently Cited Standards in the Construction Industry ......................................................................... 7
Welding, Cutting, and Brazing Checklist – Construction ............................................................................ 8
Table 2: Ventilation Requirements – Construction .................................................................................... 10

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Welding, Cutting, and Brazing

Introduction 1910.253(b)(2)(iii) Empty cylinders shall have their


valves closed.
This checklist helps employers and employees in general 1910.253(b)(2)(iv) Valve protection caps, where
industry and construction comply with the Occupational Safety cylinders are designed to accept a
and Health Administration (OSHA)’s standards for welding, cap, shall always be in place, hand-
cutting, and brazing. tight, except where cylinders are in
use or connected for use.
It is based on 29 Code of Federal Regulations (CFR) Part 1910, 1910.254(d)(9)(iii) Cables with damaged insulation or
Subpart Q, and 29 CFR Part 1926, Subpart J, OSHA Standards for exposed bare conductors shall be
the General and Construction Industry. These standards can be replaced. Joining lengths of work
found on OSHA’s web site at www.osha.gov. and electrode cables shall be done
by the use of connecting means
Employers in the construction industry should review the specifically intended for the purpose.
section dealing with general industry, because some of the The connecting means shall have
insulation adequate for the service
questions apply to all worksites. conditions.
Compliance with this checklist does not necessarily assure full
compliance with all OSHA standards.

Frequently Cited Welding Standards


in General Industry
1910.253(b)(4)(i) Oxygen cylinders shall not be stored
near highly combustible material
(especially oil and grease); near
reserve stocks of carbide, acetylene,
or other fuel gas cylinders; near any
other substance likely to cause or
accelerate fire; or in an acetylene
generator compartment.
1910.253(b)(4)(iii) Oxygen cylinders in storage shall be
separated from fuel-gas cylinders or
combustible materials (especially oil or
grease) a minimum of 20 feet or by a
noncombustible barrier at least five (5)
feet high having a fire-resistance rating
of at least one-half hour.
1910.253(b)(2)(ii) Inside buildings, cylinders shall be
stored in a well-protected, well-
ventilated, dry location at least 20 feet
from highly combustible materials such
as oil or excelsior. Cylinders should
be stored in definitely assigned
places away from elevators, stairs, or
gangways. Assigned storage spaces
shall be located where cylinders will
not be knocked over or damaged by
passing or falling objects, or subject
to tampering by unauthorized
persons. Cylinders shall not be kept
in unventilated enclosures such as
lockers or cupboards.

Texas Department of Insurance, Division of Workers’ Compensation


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HS03-004C (10-16) 1
Welding, Cutting, and Brazing Checklist for General Industry
(A negative answer to any question indicates an area of safety or health concern.)

Company name:
Physical address of worksite:
Supervisor:
Date/Time:
Inspector:

General Industry – CFR 1910

Installation and Operation of Oxygen-Fuel Gas Systems for Welding and Cutting – 1910.253
Yes No Date corrected
1. Is acetylene generated, piped, or utilized at a pressure of 30 p.s.i. absolute pressure or less? .253(a)(2)?

2. Have personnel in charge of the oxygen or fuel gas supply equipment been instructed and judged
competent before being left in charge? .253(a)(4)?

3. Is the gas content of compressed gas cylinders marked with either the chemical or the trade name
of the gas? .253(b)(1)(ii) (Also see ANSI Z48.1-1954.)

4. Are cylinders stored away from radiators and other sources of heat? .253(b)(2)(i)?

5. Are cylinders that are stored inside kept in a well-ventilated, dry location at least 20 feet from
highly combustible material? .253(b)(2)(ii)

6. Are cylinders stored in assigned places away from elevators, stairs, or gangways and where they
will not be knocked over or damaged? .253(b)(2)(ii)

7. Are the valves of empty cylinders kept closed? .253(b)(2)(iii)

8. Are valve protection caps in place and hand-tight except when in use or connected for use?
.253(b)(2)(iv)

9. Are fuel gas cylinders, except those in use or attached for use and are stored inside a building,
limited to a total gas capacity of 2,000 cubic feet or 300 pounds of liquefed petroleum gas?
.253(b)(3)(i)

10. Are acetylene cylinders stored valve end up? .253(b)(3)(ii)

11. If oxygen cylinders are stored in outside generator houses, are they separated from the generator
or carbide storage rooms by a gastight, noncombustible partition having a fre-resistance rating of
at least one hour? .253(b)(4)(ii)

12. Are stored oxygen cylinders separated from fuel gas cylinders or combustible material by a
minimum of 20 feet, or by a noncombustible barrier at least 5 feet high with a fre-resistance rating
of at least one-half hour? .253(b)(4)(iii)

13. Are cylinders, cylinder valves, couplings, regulators, hose, and apparatus kept free from oily or
greasy substances? .253(b)(5)(i)

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General Industry – CFR 1910

Installation and Operation of Oxygen-Fuel Gas Systems for Welding and Cutting – 1910.253 (cont.)
Yes No Date corrected
14. Do you ensure that cylinders are not dropped, struck, or permitted to strike each other violently?
.253(b)(5)(ii)(B)

15. Do you ensure that valve-protection caps are not used for lifting cylinders from one vertical
position to another? .253(b)(5)(ii)(C)

16. Do you ensure that cylinders without fixed hand wheels have keys, handles, or nonadjustable
wrenches on the valve stems while the cylinders are in service? .253(b)(5)(ii)(E) (NOTE: In multiple
cylinder installations, only one key or handle is required for each manifold.)

17. Are cylinder valves closed before moving cylinder and when work is finished? .253(b)(5)(ii)(F) and
(G)

18. Are cylinders kept away from sparks, hot slag, or flame produced by welding or cutting operations,
or are fire-resistance shields provided? .253(b)(5)(ii)(I)

19. Are cylinders placed where they will not become part of an electric circuit? .253(b)(5)(ii)(J)

20. Do you ensure that cylinders are not used as rollers or supports, and that only proper tools are
used to open cylinder valves? .253(b)(5)(ii)(K)

21. Are only proper tools used to open cylinder valves? 253(b)(5)(ii)(Q)?

22. Are fuel-gas cylinders placed valve end up while in use? .253(b)(5)(iii)(A)

23. Are cylinders with leaky valves or fittings taken outdoors and slowly emptied? .253(b)(5)(iii)(F)

24. Are warning signs posted that prohibit open flame or other sources of ignition near cylinders with
leaking fuse plugs or other leaking safety devices, and are the cylinders tagged? .253(b)(5)(iii)(G)
Manifold Systems – 1910.253
25. Do you ensure that oxygen manifolds are not located in an acetylene generator room? .253(c)(2)(ii)

26. Do you ensure that portable outlet headers are used indoors only for temporary service where
conditions preclude a direct supply from outlets located on the service piping system? .253(c)(4)(i)

27. Is each outlet on the service piping which supplies a portable outlet header equipped with a
readily accessible shutoff valve? .253(c)(4)(ii)

28. Are master shutoff valves for both oxygen and fuel-gas provided at the entry end of the portable
outlet header? .253(c)(4)(iv)

29. Are portable outlet headers provided with frames to support the equipment securely in the
correct operating position? .253(c)(4)(viii)

30. When acetylene cylinders are coupled in a manifold, are flash arresters installed between each
cylinder and the coupler block? .253(c)(5)(iii)

31. In service piping systems, are distribution lines installed and maintained in a safe operating
condition? .253(d)(3)(i)

32. Are emergency gas cocks or valves provided for all buildings? .253(d)(3)(v)

33. Is underground pipe and tubing and outdoor ferrous pipe and tubing protected against
corrosion? .253(d)(4)(i)

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General Industry – CFR 1910

General Requirements – 1910.253


Yes No Date corrected
34. Is flashback protection provided by an approved device that will prevent flame from passing into
the fuel-gas systems? .253(e)(3)(ii)(C)(3)

35. Are hoses showing defects repaired or replaced? .253(e)(5)(v)

36. Are pressure-reducing regulators used only for the gas and pressures for which they are intended?
.253(e)(6)(i)

37. Is the repair of regulators performed by properly instructed, skilled mechanics? .253(e)(6)(ii)

38. Are gauges on oxygen regulators marked “USE NO OIL”? .253(e)(6)(iii)

39. Are union nuts and connections on regulators inspected before use to detect faulty seats?
Acetylene Generators – 1910.253
40. Is ample space provided around the generator for operation and maintenance? .253(f )(3)

41. Are generators placed where water will not freeze, and is the use of sodium chloride to prevent
freezing prohibited? .253(f )(4)(i)(B)

42. Are portable generators located at a safe distance from the welding position? .253(f )(5)(ii)(E)

43. Are the walls, floors, and roofs of outside generator houses constructed of noncombustible
materials? .253(f )(6)(i)(B)

44. Are exit doors readily accessible in case of emergency? .253(f )(6)(i)(D)

45. Are generators installed inside buildings enclosed in a separate room? .253(f )(6)(i)(G)

46. Are the walls, partitions, floors, and ceilings of inside generator rooms of noncombustible
construction with a fire-resistance rating of at least one hour? .253(f )(6)(i)(H)

47. Are generator rooms or buildings well ventilated with vents located at floor and ceiling levels?
.253(f )(6)(ii)

48. Do generator rooms or buildings have natural light during daylight hours or artificial light
restricted to electric lamps installed in a fixed position? .253(f )(6)(iv)(A)

49. Are operating instructions posted in a conspicuous place near the generator or available for ready
reference? .253(f )(7)(i)(A)

50. Is the generator room electrically wired in accordance with 1910.307 (hazardous locations)?

51. Do you ensure that the water-carbide residue mixture drained from the generator is not
discharged into sewer pipes or stored in areas near open flames? .253(f )(7)(i)(D)

52. Do you ensure that calcium carbide is kept in metal packages that are strong enough to prevent
rupture? .253(g)(1)(i)

53. Are the packages marked “Calcium Carbide–Dangerous If Not Kept Dry”? .253(g)(1)(ii)

54. Do you ensure that the calcium carbide stored indoors does not exceed 600 pounds and that the
storage area is dry, waterproof, and well-ventilated? .253(g)(2)(i)

55. Are carbide containers that are stored outside periodically examined for conditions that could
affect water or air tightness? .253(g)(3)(ii)
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HS03-004C (10-16) 4
General Industry – CFR 1910

Application, Installation, and Operation of Arc Welding and Cutting Equipment – 1910.254
Yes No Date corrected
56. Have employees who are designated to operate arc welding equipment been properly instructed
and qualified? .254(a)(3)

57. Are open-circuit (no-load) voltages of arc welding and cutting machines as low as possible,
consistent with satisfactory welding? .254(b)(3)

58. When open-circuit voltages must be higher, are means provided to prevent the operator from
making accidental contact with the higher voltages? .254(b)(3)(iii)

59. Is control apparatus enclosed on all types of arc welding machines? .254(b)(4)(ii)

60. Are terminals for welding leads protected from accidental electrical contact by personnel or metal
objects? .254(b)(4)(iv)

61. Do you ensure that no connections for portable control devices, such as push buttons carried by
the operator, are connected to an A.C. circuit of higher than 120 volts? .254(b)(4)(v)

62. Is the frame or case of the welding machine effectively grounded, and was the grounding
checked? .254(c)(2)(i) and (d)(3)

63. Is a separate disconnecting switch or controller provided at or near each welding machine? .254(c)
(3)(i)

64. Are electrode holders placed so they cannot make electrical contact with people, conducting
objects, fuel, or compressed gas tanks? .254(d)(7)

65. Has the operator been instructed to report any equipment defect or safety hazard to a supervisor,
and is use of the equipment discontinued until repaired by qualified personnel? .254(d)(9)(i)

66. Are work and electrode lead cables frequently inspected for wear and damage, and are cables
with damaged insulation or exposed bare conductors replaced? .254(d)(9)(iii)
Installation and Operation of Resistance Welding Equipment – 1910.255
67. Have personnel who are designated to operate resistance welding equipment been properly
instructed and judged competent to operate such equipment? .255(a)(3)

68. Are all doors and access panels of all resistance welding machines and control panels kept locked
and interlocked? .255(b)(3)

69. Has a shield guard of safety glass or suitable fire-resistant plastic been installed at the point of
operation? .255(b)(5)

70. Are foot switches guarded to prevent accidental operation of the machine? .255(b)(6)

71. Are two or more safety emergency stop buttons provided on all special, multi-spot welding
machines, including 2-post and 4-post weld presses? .255(b)(7)

72. Are flash welding machines equipped with hoods to control flying flash? .255(d)(1)

73. Are periodic inspections of the machines made by qualified maintenance personnel, and are
records of the inspections maintained? .255(e)

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HS03-004C (10-16) 5
General Industry – CFR 1910

Fire Prevention and Protection – 1910.252


Yes No Date corrected
74. Is suitable fire-extinguishing equipment maintained in a state of readiness for instant use? .252(a)
(2)(ii)

75. Are fire watches on duty whenever welding or cutting is performed in locations where a major fire
might develop? (See conditions listed) .252(a)(2)(iii)(A)

76. Before cutting or welding is permitted, is the area inspected by the individual responsible for
authorized cutting and welding operations? .252(a)(2)(iv)

77. Where practicable, are all combustibles relocated at least 35 feet from the work site? .252(a)(2)(vii)

78. Does management recognize its responsibility for the safe usage of cutting and welding
equipment on its property? .252(a)(2)(xiii)

79. Do supervisors recognize their responsibilities in the safe management of welding and cutting
operations as defined in .252(a)(2)(xiv)(A)?

Protection of Personnel – 1910.252


80. Are welders or helpers who are working on platforms, scaffolds, or runways protected against
falling by railings, safety belts, or lifelines? .252(b)(1)(i)

81. Is welding cable and other equipment kept clear of passageways, ladders, and stairways? .252(b)
(1)(ii)

82. Are helmets, hand shields, goggles, or other suitable eye protection worn during all arc welding or
cutting operations? .252(b)(2)(i)(A)

83. Has a hazard assessment been performed to determine if hazards are present or likely to be
present? .132(d)(1)

84. Are employees who are exposed to the hazards created by welding, cutting, or brazing operations
protected by personal protective equipment (PPE), as required by 1910.132 and 1910.252(b)(3)?

85. When welding or cutting is being performed in any confined space, are gas cylinders and welding
machines left outside? .252(b)(4)(iii)

86. Before operations are started, is heavy, portable, wheel-mounted equipment securely blocked to
prevent accidental movement? .252(b)(4)(iii)

87. Where a welder must enter a confined space through a manhole or other small opening, have
means been provided for his or her quick removal in case of emergency? .252(b)(4)(iv)
Health Protection and Ventilation – 1910.252
88. Are welders or helpers who are working on platforms, scaffolds, or runways protected against
falling by railings, safety belts, or lifelines? .252(b)(1)(i)

89. Is welding cable and other equipment kept clear of passageways, ladders, and stairways? .252(b)
(1)(ii)

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Table 1 – Ventilation Requirements for Welding and Cutting – 29 CFR 1910
Metal Compound Confined Space Indoor Requirements Outdoor Requirements
Requirements

Fluorine Compound Air replacement or Air sample tests to


airline respirator or self- determine if exhaust
Same as indoors
contained breathing hood, booth, and airline
apparatus needed respirator are required
Lead, Zinc
(Galvanized Metals) Air replacement or Combination particulate
airline respirator or self- and vapor-and-gas-
Exhaust hood or booth
contained breathing removing type respirator
apparatus if tests indicate need
Beryllium
Exhaust hood or booth Exhaust hood or booth
Exhaust hood or booth
and airline respirator if and airline respirator if
and airline respirator if air
air sample tests indicate air sample tests indicate
sample tests indicate need
need need
Cadmium, Mercury
Combination particulate
Exhaust hood or booth Exhaust hood or booth
and vapor-and-gas-
and airline respirator if air and airline respirator if air
removing type respirator
sample tests indicate need sample tests indicate need
if tests indicate need

1. Airline or self-contained breathing apparatus are required in confined areas that are immediately hazardous to life.

2. Mechanical ventilation at 2,000 cubic feet of air per minute per welder is required when welding or cutting on metals other
than above described, or there is less than 10,000 cubic feet of space per welder or where the ceiling height is less than 16
feet or in confined spaces or where structural barriers (such as partitions or balconies) significantly obstruct cross ventilation.
1910.252(c)(2)(i)(A) through (C).

3. Local exhaust hoods or booths must provide airflow of 100 linear feet per minute.

NOTE: Mechanical ventilation is necessary when an exhaust hood or fixed booth provide for a rate of airflow sufficient to maintain a
velocity away from the welder or not less than 100 linear feet per minute.

Frequently Cited Welding Standards in the Construction Industry


1926.350(a)(9) Compressed gas cylinders shall be secured in an upright position at all times except, if necessary, for
short periods of time while cylinders are hoisted or carried.

1926.350(a)(1) Valve protection caps shall be in place and secured.

1926.350(h) Oxygen and fuel gas pressure regulators, including their related gauges, shall be in proper working
order while in use.

1926.351(b)(4) Cables in need of repair shall not be used. When a cable, other than the cable lead referred to in
subparagraph (2) of this paragraph, becomes worn to the extent of exposing bare conductors, the
portion thus exposed shall be protected by means of rubber and friction tape or other equivalent
insulation. [Note: Subparagraph (2) states that cables with standard insulated connectors or with splices
whose insulating quality is equal to that of the cable are permitted.

7
Welding and Brazing Checklist for Construction
(A negative answer to any question indicates an area of safety or health concern.)

Company name:
Physical address of worksite:
Supervisor:
Date/Time:
Inspector:

Construction – CFR 1926

Transporting, Moving, and Storing Compressed Gas Cylinders – 1926.350


Yes No Date corrected
1. Are valve protection caps in place and secured? 1926.350(a)(1)

2. When transported by powered vehicles, are cylinders secured in a vertical position? .350(a)(4)

3. Are employees instructed not to use valve protection caps to lift cylinders from one vertical
position to another? .350(a)(5)

4. Unless cylinders are firmly secured on a special carrier, have regulators been removed and are
valve protection caps in place before moving? .350(a)(6)

5. Is a cylinder truck, chain, or other steadying device used to keep cylinders from being knocked
over while in use? .350(a)(7)

6. Are cylinder valves closed when work is finished, when cylinders are empty, or when cylinders are
being moved? .350(a)(8)

7. Are cylinders secured in an upright position at all times except when hoisted or carried? .350(a)(9)
Placing Cylinders – 1926.350
8. Are cylinders kept at a safe distance from welding operations, or are fire resistant shields provided?
.350(b)(1)

9. Are cylinders placed where they cannot become part of an electrical circuit? .350(b)(2)

10. Do you ensure that cylinders containing oxygen, acetylene, or other fuel gas are not taken into
confined spaces? .350(b)(4)
Treatment of Cylinders – 1926.350
11. Do you ensure that cylinders, whether full or empty, are not used as rollers or supports? .350(c)(1)
Use of Fuel Gas – 1926.350
12. Have employees been instructed in the safe use of fuel gas as outlined in .350(d)(1) through (6)?

Fuel Gas and Oxygen Manifolds – 1926.350


13. Do fuel gas and oxygen manifolds bear the name of the substance they contain in letters at least 1
inch high, either painted on the manifolds or on a sign permanently attached to them? .350(e)(1)

14. Are the manifolds placed in safe, well-ventilated, and accessible locations and not within enclosed
spaces? .350(e)(2)

8
Construction – CFR 1926

Hoses – 1926.350
Yes No Date corrected
15. Do you ensure that oxygen and fuel gas hoses are not interchangeable and that a single hose
having more than one gas passage is not be used? .350(f )(1)

16. Are all hoses in use inspected at the beginning of each work shift, and is a defective hose removed
from service? .350(f )(3)

17. Are hose couplings of the type that cannot be unlocked or disconnected without a rotary motion?
.350(f )(5)

18. Are boxes that are used for the storage of gas hose ventilated? .350(f )(6)
Torches – 1926.350
19. Are torches in use inspected at the beginning of each shift for leaking shutoff valves, hose
couplings, and tip connections? .350(g)(2)

20. Do you ensure that torches are lighted by friction lighters or other approved devices, and not by
matches or from hot work? .350(g)(3)
Regulators and Gauges – 1926.350
21. Are oxygen and fuel gas regulators and their gauges in proper working order? .350(h)

Oil and Grease Hazards – 1926.350


22. Do you ensure that cylinders, cylinder caps, valves, couplings, regulators, hose and apparatus are
kept free from oil or greasy substances, and are not handled with oily hands or gloves? .350(i)
Welding Cables and Connectors – 1926.351
23. Do you use only cable that is free from repair or splices for a minimum of 10 feet from the cable
end to which the electrode holder is connected? .350(b)(2) (NOTE: Cables with standard insulated
connectors or with splices whose insulating quality is equal to that of the cable are permitted.)

24. Do you ensure that cables in need of repair are not used? .351(b)(4)
Operating Instructions – 1926.351
25. Have employees been instructed in the safe means of arc welding and cutting as prescribed in
.351(d)(1) through (4)?

26. Are arc welding and cutting operations shielded by noncombustible or flameproof screens?
.351(e)
Fire Prevention – 1926.352
27. Have employees been instructed that objects to be welded, cut, or heated must be moved to a
designated location, or that movable fire hazards be taken to a safe place or otherwise protected?
.352(a)

28. Is suitable fire-extinguishing equipment that is ready for instant use available in the work area?
.352(d)
Ventilation and Protection – 1926.353
29. Are employees protected by airline respirators in confined spaces when sufficient ventilation
cannot be obtained without blocking the means of access? .353(b)(2)

30. Do welding, cutting, and heating operations using toxic substances meet the requirements of
.353(a) and (c)?

9
Construction – CFR 1926
Ventilation and Protection – 1926.353 (cont.)
Yes No Date corrected
31. Are welders and other employees who are exposed to radiation suitably protected? .353(d)(1)(iii)

32. Are employees who are performing any type of welding, cutting, or heating protected by suitable
eye protective equipment? .353(e)(2)
Preservative Coatings – 1926.354
33. If the flammability of a preservative coating is unknown, is a test made by a competent person to
determine its flammability? .354(a)

34. Are employees protected against toxic preservative coatings as prescribed in .354(c)(1) and (2)?
Table 2: Ventilation Requirements for Welding and Cutting – 29 CFR 1926
Metal Compound Confined-Space Enclosed-Space Open-Air Requirements
Requirements Requirements

Mechanical Mechanical
All Metals ventilation or ventilation or N/A
exhaust hood exhaust hood

Zinc-bearing base or
filler metals; lead base
Mechanical Mechanical
metals; cadmium- Combination particulate and vapor-and-gas-removing
ventilation or ventilation or
bearing filler type respirator if tests indicate the need
exhaust hood exhaust hood
materials; chromium-
bearing metals

Metals containing
lead or coated
with lead-bearing
Mechanical
materials; cadmium- *Exhaust hood or Combination particulate and vapor-and-gas-removing
ventilation or
bearing or cadmium- airline respirator type respirator if tests indicate the need
exhaust hood
coated base metals;
mercury-bearing
metals

Mechanical
Beryllium-containing *Exhaust hood or
ventilation or Airline respirator if tests indicate the need
base or filler metals airline respirator
exhaust hood

*Freely movable hood placed by the welder as near as practicable to the work being welded, with a rate of airflow sufficient to
maintain a velocity in the direction of the hood of 100 linear feet per minute in the zone of welding when the hood is at its most
remote distance from the point of welding.

Unless otherwise noted, this document was produced by the Division of Workers’ Compensation (DWC) using information from
staff subject specialists, governmental entities, or other authoritative sources. It is considered accurate at the time of publication.

For more free DWC safety and health publications, visit www.tdi.texas.gov/wc/safety/videoresources/index.html.

DWC features a free occupational safety and health audiovisual loan library. Call (800) 252-7031, option 2, for more information or
visit the TDI website at www.tdi.texas.gov/wc/safety/videoresources/avcatalog.html.

DWC Workplace Safety: (800) 252-7031, option 2, or resourcecenter@tdi.texas.gov.


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HS03-004C (10-16) 10